Abstract
Aluminum alloy material is used for a lot of railroad cars such as SHINKANSEN and the commuting train. The carbody is composed A6N01S extrusion of aluminum alloy material and manufactured with MIG welding process. New joining process "Friction Stir Welding (FSW)" is developed in TWI in 1991. Because FSW is a low heat input process compared with MIG welding, the distortion of welding joint can be reduced. With using the advantage of FSW, the application is started in 1998. The first application is joining parts of carbody side-panel. After the hollow shape extrusion is developed, FSW has extended to the primary parts of the carbody structure, such as roof-panel, side-panel and floor-panel. About ten years pass from the first application FSW is becoming the main joining process of the aluminum alloy carbody.
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